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Professional article/Strokovni ~lanek
ISSN 1580-2949
MTAEC9, 48(1)149(2014)
B. ZORC et al.: INFLUENCE OF NON-METALLIC INCLUSIONS ON THE FORMATION OF HOT CRACKS ...
Prejem rokopisa received: 2013-04-04; sprejem za objavo accepted for publication: 2013-05-15
A thick-walled casting of unalloyed cast steel with a high content of non-metallic inclusions was built up with the submerged
arc-welding (SAW) process. Hot cracks were detected in the built-up, tough inner layer of unalloyed steel (near the fusion line
alongside the edge of the prepared groove). The cause for it was an inappropriate "bead-to-bead" technique of building up, with
a strong remelting of the base material and a strong contamination of the weld pool with non-metallic inclusions. The chemical
composition of the inclusions also indicated an insufficient attention or technical difficulties during building, since some
inclusions were based on the welding slag. The smallest possible content of the base-material admixture must be ensured, the
welding slag fully removed and, if needed, before welding the next bead, the narrow and deep interpass groove must be widened
and rounded off by grinding.
Keywords: surfacing, non-metallic inclusions, strong remelting of the base metal, hot cracking
Pri debelostenskem ulitku iz nelegirane jeklene litine z veliko vsebnostjo nekovinskih vklju~kov, navarjenem po postopku
varjenja pod pra{kom (EPP), so bile v navarjeni `ilavi vmesni plasti iz nelegiranega jekla v prvem sloju oziroma blizu linije
spajanja ob robu pripravljenega utora ugotovljene vro~e razpoke. Vzrok je bila neprimerna tehnika navarjanja "varek do varka",
kar je imelo za posledico mo~no pretaljevanje osnovnega materiala in zato mo~no onesna`enje zvarne kopeli z nekovinskimi
vklju~ki. Kemijska sestava vklju~kov ka`e tudi na nepazljivost ali na tehnolo{ke te`ave med navarjanjem, saj so nekateri
vklju~ki na osnovi varilske `lindre. Nujno je zagotoviti ~im manj{e prime{anje osnovnega materiala, dobro odstraniti varilsko
`lindro in pred varjenjem naslednjega varka po potrebi z bru{enjem raz{iriti in zaobliti nastale ozke in globoke medvarkovne
`lebove.
Klju~ne besede: navarjanje, nekovinski vklju~ki, mo~no pretaljevanje osnovnega materiala, pokljivost v vro~em
1 INTRODUCTION
Cracks and ruptures always form due to an excessive
tensile-stress concentration at the places of their
nucleation due to different causes. One possible cause is
the global overload of the construction. When dealing
with calculated acceptable loads, an important role is
played by the local-construction fatigue-notch factors
and local metallurgical factors of the metal (segregation,
intercrystalline impurities and brittle phases, coarse
non-metallic inclusions such as slag inclusions and
remains of the moulding sand, etc.). Constructional
faults and metallurgical defects cause an occurrence and
propagation of cracks at the stresses lower than the
materials tensile strength or even the yield strength (the
latter is characteristic of fatigue cracks). In this case, the
construction overloading does not equal the material
overloading. Due to unfamiliar metallurgical negative
factors, the material overloading cannot be reliably stress
determined, timed or calculated.
Among the metallurgically caused cracks there are
also intercrystalline hot cracks (crystallization, liquation
and polygonization cracks) that form during welding at
Materiali in tehnologije / Materials and technology 48 (2014) 1, 149154
B. ZORC et al.: INFLUENCE OF NON-METALLIC INCLUSIONS ON THE FORMATION OF HOT CRACKS ...
Figure 1: Microstructural characteristics of the cast-steel base material: a) normalized ferrite-pearlite microstructure with non-metallic
inclusions (dark dots in the ferrite); b), c) unevenly arranged inclusions of various shapes (unetched)
Slika 1: Mikrostrukturne zna~ilnosti navarjene jeklene litine: a) normalizirana feritno-perlitna mikrostruktura z nekovinskimi vklju~ki
(temne pike v feritu); b), c) neenakomerno razporejeni vklju~ki razli~nih oblik (nejedkano)
Materiali in tehnologije / Materials and technology 48 (2014) 1, 149154
B. ZORC et al.: INFLUENCE OF NON-METALLIC INCLUSIONS ON THE FORMATION OF HOT CRACKS ...
(1)
Figure 3: Cross-section through the part of a soft built-up interlayer (b. m. base material, s. i. soft interlayear, h. w. hard surfacing metal)
Slika 3: Pre~ni prerez skozi del navarjene mehke plasti (b. m. osnovni material, s. i. mehka vmesna plast, h. w. trdi navar)
Materiali in tehnologije / Materials and technology 48 (2014) 1, 149154
151
B. ZORC et al.: INFLUENCE OF NON-METALLIC INCLUSIONS ON THE FORMATION OF HOT CRACKS ...
multi-pass welds, the coarse columnar grains (pro-eutectoid ferrite at the grain boundaries, a fine acicular
ferrite-carbide aggregate inside the grains, Figure 2a)
and the reheated zones (a normalized ferrite-perlite
microstructure, Figures 2b and 2c) exist in the deposited
layers.
Based on the results of the chemical analysis and the
high impact toughness, it can be concluded that the used
welding parameters were appropriate. All the weld metal
is well resistant to hot cracking, since, according to the
measured values of the chemical elements, the index of
the hot-crack susceptibility UCS 13.8 is low. A problem arises when a significant quantity of the weld metal
is contaminated with the base material with a high content of non-metallic inclusions and with a high content of
carbon.
3.3 Analysis of the region with a built-up interlayer
The interlayer with a thickness of approximately 15
mm consisted of multilayers with a distinct wavy fusion
boundary between the first layer and base material
(Figure 3), revealing the "bead-to-bead" build-up welding technique with a minimum overlapping of the neighbouring beads. The very deep bead penetration into the
base material (Figure 4a) caused a large admixture of
the base material into the first built-up layer and the
chemical composition of the first layer was (w/%): C =
0.180.23; Si = 0.230.27; Mn = 0.730.76; P =
0.0230.024; S = 0.0190.021. The first beads, thus,
consist of approximately 6075 % of the base material.
In the heat-affected zone (HAZ) the lines between individual beads reveal the leaning towards the outer edge of
Figure 4: Hot cracks in the built-up interlayer and the base-material HAZ: a) cracks in the edge beads of the built-up interlayer, b) cluster of
inclusions with the cracks in the base-material HAZ, c) cracks on the boundaries of the columnar grains in the welds
Slika 4: Vro~e razpoke v navaru vmesne plasti in TVC osnovnega materiala: a) razpoke v robnih varkih navarjene vmesne plasti, b) gnezdo
vklju~kov z razpokami v TVC osnovnega materiala, c) razpoke na mejah transkristalnih zrn v navaru
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B. ZORC et al.: INFLUENCE OF NON-METALLIC INCLUSIONS ON THE FORMATION OF HOT CRACKS ...
B. ZORC et al.: INFLUENCE OF NON-METALLIC INCLUSIONS ON THE FORMATION OF HOT CRACKS ...
154
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